Devices, systems and methods for anchoring structural loads

ABSTRACT

Disclosed are devices, systems and methods for anchoring buildings to foundations. The disclosed devices, methods and systems comprise an embedment block comprising fasteners attaching a load bearing structure to a foundation anchor. Anchors comprise a head such as pierhead, loop, or plate or other assemblies that easily affix the anchor to its load.

BACKGROUND

High load bearing structures such as building columns require anchorpiles attaching to and extending below a building's foundation. Anchorpiles are often used where a shallow foundation is insufficient due to avariety of reasons including large structural loads. Unfortunately,building pilings often require drilling large and deep holes in theearth to set reinforced concrete or otherwise require driving largemetal spikes into the ground. After reinforced concrete pilings set,they are susceptible to shear and torsion forces that can crack ordisplace the pilings. Use of unreinforced concrete foundations, termed“floating” foundations, are limited to situations where the weather isfavorable and the soil is suitable for pouring shallow foundations.

Moreover, load-bearing pilings, such as those providing support forarches, columns, and other structures must be connected to each other bya system of footings linked to the foundation, creating additionalweight and structural risk of shear and torsional weaknesses between thestructural components. In some instances, steel helical anchors havebeen used instead of concrete pilings. However, the sectional diameterof such anchor heads or piers are small thereby requiring elaboratemating joints to connect the load bearing structure. Thus, what isneeded are devices, systems and methods that do not require pilings toanchor load bearing structures; as well as devices, systems and methodsthat eliminate mating joints between a load bearing structure and ananchor, but retain the necessary stability and strength to anchor thestructure to the earth.

SUMMARY

Presented herein are devices, systems and methods for joining a loadbearing structure, such as a column, for example, to an anchor withoutneed for a mating assembly. In one embodiment, the device is anintegrated embedment block holding together (or capable of holdingtogether) the head of an anchor and a fastener for a load bearingstructure such as a column, beam, arch, etc. In one embodiment, a methodof embedding the head of an anchor into a concrete block with anintegrally attached fastener for a load bearing structure is disclosed.In yet another embodiment, a system of transferring load forces from aload-bearing structure into an embedment block and subsequently into anembedded anchor is described. The disclosed devices, systems and methodsdo not rely on mating assemblies connecting the load-bearing structureand the anchor, and specifically are intended to exclude suchassemblies, including mating assemblies between a load-bearing foot anda load-bearing anchor head. While not limited to use in construction,such a system is specifically intended to allow the rapid erection of astructure in situations where weather and soil conditions areunfavorable including using a floating foundation in boggy soil. Varioususes included construction of buildings, pre-engineered buildings,bridges, piers, pipelines and other structures benefiting from afoundation anchor.

Certain benefits are realized by the devices, systems and methodsdisclosed herein. The particular arrangement of a fastener for a loadbearing structure embedded into the same block as an anchor head enjoysthe benefits of a floating concrete foundation, such as lighter weight,while retaining the benefits of a piling-anchored foundation, which hadbeen mutually exclusive until disclosed herein. The disclosed devices,systems and methods lack the need for a mating assembly between a loadbearing structure and an anchor. Similarly, the disclosed devices,systems and methods reduce the time and cost of constructing abuilding's foundation as well as create a strong, lightweight anddurable joint between the anchor and the load-bearing structure.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 illustrates an overhead view of an exemplary embedment block usedto anchor an endwall column.

FIG. 2 illustrates a sideview of an exemplary embedment block used toanchor an endwall column.

FIG. 3 illustrates an overhead view of an exemplary embedment block usedto anchor a sidewall column.

FIG. 4 illustrates a sideview of an exemplary embedment block used toanchor a sidewall column.

FIG. 5 illustrates an overhead view of an exemplary embedment block usedto anchor a centerwall column.

FIG. 6 illustrates a sideview of an exemplary embedment block used toanchor a centerwall column.

FIG. 7 illustrates a hex bolt fastener having a threaded end forreceiving nuts embedded into the top of an embedment block.

FIG. 8 illustrates a bolt fastener embedded into the top of an embedmentblock.

FIG. 9 illustrates an epoxied bolt integrally attached to the top of anembedment block.

FIG. 10 illustrates curved bolt fastener embedded into the top ofembedment block.

DETAILED DESCRIPTION

Disclosed are devices, systems and methods for fixing a load bearingstructure to an anchored foundation. The disclosed devices, methods andsystems rely on transfer of forces from the load bearing structurethough a concrete embedment block into the head of an embedded anchorwithout the need for a direct mechanical mating assembly between theload bearing structure's foot and its anchor's head.

In certain embodiments, the term “embedment block” comprises concrete,cement, or other castable material but specifically excludes matingassemblies coupling an embedded anchor head and an embedded loadattachment point. Similarly, the term “anchor” refers to any device orcombination of devices that fix a structure to the ground, and includebut are not limited to helical anchors, piles, cables, and the likeextending into the ground. Anchors comprise a head such as pierhead,loop, or plate or other assemblies that easily affix the anchor to itsload. The term “mating assembly” is to be construed as any mechanicalassembly linking a load-bearing base and an anchor head togetherincluding such devices as couplers. The disadvantages of using suchdevices as couplers in an embedment block, such as increased weight,cost and time to construct are thereby eliminated as disclosed herein.

In certain embodiments, the embedment block comprises fasteners forattaching a load bearing structure to the top of an embedment block. Theterm “fastener” is to be construed as any device or combination ofdevices for linking the foot of a load bearing structure to an embedmentblock, and include screws, bolts, hex bolts, nut and bolts, curvedbolts, pins, rivets, resins, epoxy, and the like, operating alone or incombination with each other. The term “load-bearing” can refer to anydevice or combination of devices that transmits force downwards andinclude such structures as columns, studs, beams, arches, and the like.Load-bearing structures may comprise a “foot” that may include platesand the like for attaching the base of the load bearing structures tofasteners in an embedment block. The term “membrane skirt” includes anyconcrete slab insulation or vapor barrier designed to provide a thermalbreak or moisture barrier between a slab and a grade and includes but isnot limited to multilayer blanket insulation, cross woven polyethylene,high density closed-cell foam, high density polyethylene bubble,reflective aluminum, and the like.

In FIG. 1 a simplified top-down view of a non-limiting embodiment of thedisclosure wherein an anchor head 1, also known as a pierhead, isembedded at the bottom of a concrete embedment block 2, surrounded byrebar 3, wherein the embedment block also comprises four attachmentbolts 4, at the top of the embedment block to fasten a load bearingstructural column to the fasteners. The position of the embedment blockis shown in relation to the foundation 5, wherein the embedment block islocated at the end of two perpendicular walls (not shown).

In FIG. 2 a simplified side view of a non-limiting embodiment of thedisclosure is shown wherein an anchor head 1, also known as a pierhead,is embedded into the bottom of a concrete embedment block 2, surroundedby rebar 3 wherein the embedment block also comprises four attachmentbolts 4, at the top of the embedment block to affix a load bearingstructural column to the fasteners. The position of the embedment blockis shown in relation to the foundation 5, wherein the embedment block islocated at the end of two walls that are perpendicular to each other(not shown). The pierhead 1, is attached to a shaft extending into theground via a coupler 6, wherein the shaft comprises multiple helicalblades 7 forming a helical pile 8 thereby anchoring a load bearingstructure to the ground (not shown). Optionally, a membrane skirt 9 maybe attached to the embedment block wherein the skirt extends outwardsfrom a building.

In FIG. 3 a simplified top-down view of a non-limiting embodiment of thedisclosure is shown wherein an anchor head 1, also known as a pierhead,is embedded at the bottom of a concrete embedment block 2, surrounded byrebar 3, wherein the embedment block also comprises four attachmentbolts 4, at the top of the embedment block to fasten a load bearingstructural column to the fasteners. The position of the embedment blockis shown in relation to the foundation 5, wherein the embedment block islocated at underneath a length of a side wall (not shown).

In FIG. 4 a simplified side view of a non-limiting embodiment of thedisclosure is shown wherein an anchor head 1, also known as a pierhead,is embedded into the bottom of a concrete embedment block 2, surroundedby rebar 3 wherein the embedment block also comprises four attachmentbolts 4, at the top of the embedment block to affix a load bearingstructural column to the fasteners. The position of the embedment blockis shown in relation to the foundation 5, wherein the embedment block islocated at the center of the length of a wall (not shown). The anchorheads are attached to shafts extending into the ground via a coupler 6,wherein the shaft comprises multiple helical blades 7 forming a helicalpile 8, thereby anchoring a load bearing structure to the ground (notshown). The helical piles are offset at an angle 10 thereby distributingthe load over a greater cross-section area of ground beneath the wall.Optionally, a membrane skirt 9 may be attached to the embedment blockwherein the skirt extends outwards from a building.

In FIG. 5 a simplified top-down view of a non-limiting embodiment of thedisclosure is shown wherein an anchor head 1, also known as a pierhead,is embedded at the bottom of a concrete embedment block 2, surrounded byrebar 3, wherein the embedment block also comprises four attachmentbolts 4, at the top of the embedment block to fasten a load bearingstructural column to the fasteners. The position of the embedment blockis shown in relation to the foundation 5, wherein the embedment block islocated at the center of a length of a wall (not shown).

In FIG. 6 a simplified side view of a non-limiting embodiment of thedisclosure is shown wherein an anchor head 1, also known as a pierhead,is embedded into the bottom of a concrete embedment block 2, surroundedby rebar 3 wherein the embedment block also comprises four attachmentbolts 4, at the top of the embedment block to affix a load bearingstructural column to the fasteners. The position of the embedment blockis shown in relation to the foundation 5, wherein the embedment block islocated at the center of a length of a wall (not shown). The anchorheads 1, are attached to shafts extending into the ground via a coupler6, wherein the shaft comprises multiple helical blades 7 forming ahelical pile 8, thereby anchoring a load bearing structure to the ground(not shown). The helical piles are offset at an angle 10 therebydistributing the load over a greater cross-section area of ground.Optionally, a membrane skirt 9 may be attached to the embedment blockwherein the skirt extends outwards from a building.

In FIG. 7, a simplified side view of a non-limiting embodiment of thedisclosure is shown comprising a bolt fastener 11, embedded into the topof an embedment block 12, wherein the bolt comprises a threaded end 13with an attached nut 14 above an attachment plate 15.

In FIG. 8, a simplified side view of a non-limiting embodiment of thedisclosure is shown comprising a bolt fastener 11, embedded into the topof an embedment block 12, wherein the bolt comprises opposing threadedends 13 with attachments nuts 14 above and below an attachment plate 15.

In FIG. 9, a simplified side view of a non-limiting embodiment of thedisclosure is shown comprising a bolt fastener 11, embedded into the topof an embedment block 12, wherein the bolt comprises threads 13 with anattached nut 14 above an attachment plate 15 further wherein the boltfastener 11 is affixed in an epoxy resin 16.

In FIG. 10, a simplified side view of a non-limiting embodiment of thedisclosure is shown comprising a bolt fastener 11, embedded into the topof an embedment block 12, wherein the bolt comprises a threaded end 13with an attached nut 14 above an attachment plate 15, also wherein thefastener bolt is bent at 90° degrees 17 within the embedment block.

In certain other embodiments, a plurality of anchors are used, such astwo, three, four or more anchors. As such, a plurality of anchor headsare also embedded into the embedment block. Anchors may be sunk parallelto an attached wall or extend outwards at an angle of 120° degrees, orother suitable offset from parallel. An anchor head may comprise a piercap as shown in the Figures, but the pier cap is considered optional andthe anchor head may be used without a pier cap in some embodiments,particularly where a helical pile has shifted prior to pouring theembedment block. In certain embodiments wherein a pier cap is excluded,the bare anchor head may be affixed to rebar that is to be embedded inthe embedment block.

In order to construct the devices disclosed herein, various methods areused. In certain embodiments, a foundation trench line for a building isfirst excavated. Next, one or more helical piers are sunk into theground in the trench positions where load bearing columns are to beaffixed. Helical piers are sunk into the trench positions such that atleast the pierheads extends upward from the trench. Optionally, formersand rebar may be placed around the pierhead or surround the pierhead toform a cast. Concrete is then poured over the pierheads to cast anembedment block wherein the pierhead is embedded. Subsequently,fasteners are either embedded into the block while the concrete is stillwet, or, later, integrally attached to the block by setting fastenersinto drilled holes with epoxy or other resins. An embedment block may beformed prior to laying a foundation or formed simultaneously whilepouring a foundation. In certain embodiments, a membrane skirt isembedded or attached to the edge of the embedment block to act asinsulation and a moisture barrier prior to pouring the concrete.

In certain embodiments, the embedment block comprises a membrane skirtembedded or attached to the edge of the embedment block extending intothe ground away from the foundation and acting as insulation and amoisture barrier. For buildings susceptible to frost heave, thecombination of the embedment block and membrane skirt are especiallyadvantageous. Specifically, the interior temperature of a heatedbuilding will transfer heat to the embedment block, but the addition ofa membrane skirt will retain the heat being transferred, therebypreventing or mitigating the freezing of the ground under the skirt andaround the embedment block.

Other modifications and embodiments of the invention will come to mindin one skilled in the art to which this invention pertains having thebenefit of the teachings presented herein. Therefore, it is to beunderstood that the invention is not to be limited to the specificembodiments disclosed. Although specific terms are employed, they areused in generic and descriptive sense only and not for purposes oflimitation, and that modifications and embodiments are intended to beincluded within the scope of the appended claims.

What is claimed is: 1-18. (canceled)
 19. A method of anchoring a loadbearing structure comprising: digging a trench, anchoring at least onehelical pile at a position in the trench where a load bearing structurewill be placed, wherein the helical pile comprises a pierhead, forming acast within the trench for embedding the pierhead into an embedmentblock, pouring concrete into the cast to form an embedment block havinga top and a bottom, integrally inserting fasteners for affixing the loadbearing structure into the top of the embedment block, and, affixing aload bearing structure to the fasteners.
 20. The method of claim 19,wherein the load bearing structure is selected from the group consistingof an endwall column, a centerwall column, and a sidewall column. 21.The method of claim 19, wherein the fasteners are selected from thegroup consisting of screws, bolts, hex bolts, curved bolts, pins,rivets, resins, and epoxy, and combinations thereof.
 22. The method ofclaim 19, wherein the anchoring of the at least one helical pilecomprises anchoring a plurality of helical piles such that a pluralityof the pierheads are embedded in the embedment block.
 23. The method ofclaim 19, wherein the embedment block excludes a mating assembly thatdirectly links the pierhead and the fastener.
 24. The method of claim19, wherein the load bearing structure is a column.
 25. A system foranchoring a load bearing structure to ground comprising: an at least onehelical pile sunk into the ground with a pierhead extending above theground, wherein the pierhead is embedded into an entrenched concreteembedment block having a top and a bottom, and, wherein the top of theblock comprises integrally inserted fasteners for attaching a loadbearing structure.
 26. The system of claim 25, wherein the load bearingstructure is selected from the group consisting of an endwall column, acenterwall column, and a sidewall column.
 27. The system of claim 25,wherein the fasteners are selected from the group consisting of screws,bolts, hex bolts, curved bolts, pins, rivets, resins, and epoxy, andcombinations thereof.
 28. The system of claim 25, wherein the at leaston helical pile comprises a plurality of the helical piles such that aplurality of the pierheads are embedded into the block.
 29. The systemof claim 25, wherein the embedment block excludes a mating assembly thatdirectly links the pierhead and the fastener.
 30. The system of claim25, wherein the load bearing structure is a column.
 31. A system foranchoring a load bearing structure to ground consisting essentially of:an at least one helical pile sunk into the ground with an exposedpierhead, wherein the pierhead is embedded into an entrenched concreteembedment block having a top and a bottom, and, wherein the top of theblock comprises integrally inserted fasteners for attaching a loadbearing structure.
 32. The system of claim 31, wherein the load bearingstructure is selected from the group consisting of an endwall column, acenterwall column, and a sidewall column.
 33. The system of claim 31,wherein the fasteners are selected from the group consisting of screws,bolts, hex bolts, curved bolts, pins, rivets, resins, and epoxy, andcombinations thereof.
 34. The system of claim 31, wherein the at leastone helical pile comprises a plurality of helical piles such that aplurality of the pierheads are embedded in the embedment block.
 35. Thesystem of claim 31, wherein the embedment block excludes a matingassembly between the pierhead and the fastener that directly links thepierhead and fastener.
 36. The system of claim 31, wherein the loadbearing structure is a column.